Pole sander

ABSTRACT

A pole sander is provided including an elongate body having a first end and a second end and forming a passageway, a sanding head attached via a pivot mechanism to the first end of the elongate body and including an output spindle projecting into a chamber, an electric motor mounted on the sanding head, and a rear housing mounted on or proximate the second end of the elongate body including control electronics therein to control the motor via an electric cable. At least a portion of the electric cable locates against a flexible pipe connecting the passageway to the sanding head.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority, under 35 U.S.C. § 119, to GB PatentApplication No. 1915324.6 filed Oct. 23, 2019, GB Patent Application No.1919261.6 filed Dec. 23, 2019, and GB Patent Application No. 1919262.4filed Dec. 23, 2019.

FIELD

The present invention relates to a pole sander.

BACKGROUND

Pole sanders typically comprise a telescopic pole with a sanding headpivotally mounted on one end. The sanding head comprises a hood whichsurrounds a platen which is mounted on an output spindle which projectsfrom the hood. Sandpaper can be attached to the platen for sanding awork surface. Alternatively, a polishing pad can be attached to polish awork surface. The output spindle and hence the platen, is rotated by anelectric motor. The electric motor can be mounted on the sanding head.The motor can be controlled using control electronics which can bemounted on the opposite end of the elongate rod. A vacuum cleaner can beattached to the sanding head, typically via a pipe which extends throughthe telescopic pole, to remove dust generated by the sanding action ofthe rotating platen from under the hood.

Poles sanders can perform different surface treatments such as sanding,polishing, grinding or rubbing work surfaces.

Examples of pole sanders are disclosed in EP0727281, EP2033738,DE102014103019, WO2014/086873, EP3083139 and DE102014112355.

SUMMARY

According to an embodiment, a pole sander is provided including anelongate body having a first end and a second end; a sanding headattached via a pivot mechanism to the first end of the elongate body,wherein the sanding head comprises a hood having a plate, a chamberformed under the plate, and an output spindle projecting into thechamber; an electric motor mounted on the sanding head and configured torotatably drive the output spindle; a rear housing mounted on orproximate the second end of the elongate body, the rear housingincluding control electronics therein configured to control the motorvia an electric cable; a tubular passage coupled to an aperture formedthough the plate; a passageway formed in the elongate body to transportair; and a flexible pipe connecting the tubular passage to the elongatebody to provide an airflow path between the chamber and the passageway.In an embodiment, at least a part of the electric cable locates againsta side of the flexible pipe.

In an embodiment, a tubular sheaf surrounds both the flexible pipe andthe at least part of the cable to fixedly support the electrical cableagainst the flexible pipe.

In an embodiment, the motor is connected to the control electronics viaa single continuous electric cable via which the electronic controlsignals and/or sensor signals are transmitted.

In an embodiment, the elongate body includes a secondary passagewayextending substantially through the length of the elongate body andforming a conduit through which the electric cable passes.

In an embodiment, the elongate body includes a first pole and a secondpole are capable of sliding in and out of each other in a telescopicmanner.

In an embodiment, at least one of the first pole and/or the second poleis manufactured from metal tubing.

In an embodiment, the first pole includes a single aluminium tube withan internal wall to form a part of the passageway and a part of asecondary passageway.

In an embodiment, the second pole includes a first tube and a secondtube mounted in parallel to the first tube inside of the first tube.

In an embodiment, an end of the second tube of the second pole locatesinside a part of the passageway located inside the first pole, and thesecond tube and an internal wall of the first pole locate inside thefirst tube.

In an embodiment, the second tube of the second pole forms part of thepassageway.

In an embodiment, the first tube of the second pole forms a conduit thatis a part of the secondary passageway.

In an embodiment, the electric cable passes through the conduit.

In an embodiment, at least a part of the electric cable located insidethe conduit is helical.

In an embodiment, a pole sander is provided including an elongate bodyhaving a first end and a second end; a front housing mounted on orapproximate the first end of the elongate body; a sanding head attachedvia a pivot mechanism to the front housing, wherein the sanding headcomprises a hood having a plate, a chamber formed under the plate, andan output spindle rotatably projecting into the chamber; an electricmotor mounted on the sanding head configured to rotatably drive theoutput spindle; a rear housing mounted on or proximate the second end ofthe elongate body, the rear housing including control electronicstherein configured to control the motor; a tubular passage coupled to anaperture formed though the plate; a first passageway formed in theelongate body to transport air; a flexible pipe connecting the tubularpassage to the front housing to provide an airflow path between thechamber and the first passageway; and a second passageway formed in theelongate body. In an embodiment, the control electronics areelectrically coupled to the electric motor via a cable disposed withinthe second passageway.

In an embodiment, the cable is a single continuous cable extending fromthe electric motor to the rear housing.

In an embodiment, a part of the electric cable located between theelectric motor and the front housing is secured against a side of theflexible pipe.

In an embodiment, a tubular sheaf surrounds both the flexible pipe andthe at least part of the cable to fixedly support the electrical cableagainst the flexible pipe.

In an embodiment, the elongate body includes a first pole and a secondpole are capable of sliding in and out of each other in a telescopicmanner.

In an embodiment, the first pole includes an internal wall to form apart of the first passageway and a part of a secondary passageway.

In an embodiment, the second pole includes a first tube and a secondtube mounted in parallel to the first tube inside of the first tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations and are notintended to limit the scope of the present disclosure.

FIG. 1 shows a top view of the pole sander;

FIG. 2 shows a side view of the pole sander;

FIG. 3 shows a vertical cross-sectional view of the pole sander;

FIG. 4 shows a perspective view of the sanding head;

FIG. 5 shows an underside view of the sanding head with the platenremoved;

FIG. 6A shows a vertical cross-sectional view of the edge of the sandinghead;

FIG. 6B is the same as FIG. 6A with the addition of hatching to showcross sectional area of gap between edge of the platen and the innerwall;

FIG. 7 shows a perspective view of the brush ring;

FIG. 8 shows a view of part of the top side of the plate with the leafspring of the brush ring 132 passing through an aperture from below theplate to attach to the top side of the plate;

FIG. 9 shows a schematic diagram showing how the two poles of theelongate body are telescopically connected to each other;

FIG. 10 shows the seals which connect between the two poles of theelongate body;

FIG. 11A shows the seal for the first pole 196 being attached to thefirst pole 196;

FIG. 11B shows a vertical cross section of the seal for the first pole196 being attached to the first pole 196;

FIG. 11C shows the seal for the first pole 196 mounted on the first pole196;

FIG. 12 shows the seals adjacent the ends of the aluminium tubes of thepoles;

FIG. 13 shows a perspective cross section showing how the aluminiumtubes and seals of the two poles of the elongate body are telescopicallyconnected to each other;

FIG. 14 shows a perspective cross section showing how the aluminiumtubes and seals of the two poles of the elongate body are telescopicallyconnected to each other;

FIG. 15 shows a top view of the sanding head;

FIG. 16 shows a vertical cross section of the sanding head and lower endof the first pole 196;

FIG. 17 shows the underside view of the sanding head including theplaten;

FIG. 18 shows the platen;

FIG. 19 shows the rear housing with one of the clam shells removed;

FIG. 20 shows a vertical cross section of the rear housing;

FIG. 21 shows a top perspective view of the sanding head;

FIG. 22 shows the extension tube inside the handle section of the rearhousing with the vacuum nozzle detached;

FIG. 23 shows the extension tube inside of the handle section of therear housing with the vacuum nozzle attached;

FIG. 24 shows the rear end of the extension tube with the vacuum nozzledetached;

FIG. 25 shows the rear end of the extension tube with the vacuum nozzleattached;

FIG. 26A and FIG. 26B show a first angle of the tubular passageway ofthe hood; and

FIG. 27A and FIG. 27B shows a second angle of the tubular passageway.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Referring to FIGS. 1 to 3, the pole sander comprises a sanding head 100pivotally attached to one end of an elongate body 102 and a rear housing104 attached to the other end.

The elongate body 102 is telescopic and is formed from two poles 196,198, one of which slides in an out of the other as described in moredetail below.

The sanding head 100 connects to the end of the elongate body 102 via apivot mechanism 110 which is described in more detail below. The sandinghead 100 comprises a hood 112 on top of which is mounted an electricmotor 114. The motor 114 is a DC brushless motor 114. The motor 114 isenclosed by a motor housing 120 which is cup shaped and surrounds thetop and sides of the motor 114. The motor housing 120 attaches to thetop of a gear housing 122 which encloses a planetary gear set 124. Thegear housing 122 mounts on top of the hood 112. The motor 114 isdrivingly connected via the planetary gear set 124 to an output spindle118 having a longitudinal axis 126 about which the output spindle 118rotates and which is located below the hood 112. Attached to the end ofoutput spindle 118 is a circular platen 116 which extends radiallyoutwards from the output spindle 118. When the motor 114 is activated,the motor 114 rotationally drives the output spindle 118 and hence theplaten 116 about a drive axis 126.

A flexible dust extraction pipe 128 attaches to the top of the hood 112on one side of the motor 114. An aperture 130 is formed through the hood112. The end of the flexible pipe 128 surrounds the aperture 130. Assuch air can be drawn from beneath hood 112 through the aperture 130 andinto the flexible pipe 128. This enables dust and debris generatedduring the operation of the pole sander to be removed from under thehood 112 by applying a suction force to the flexible pipe 128. Theoperation of the dust extraction of the pole sander is described in moredetail below.

A brush ring 132 attaches to the edge of the hood 112. The brush ring132 is described in more detail below.

The rear housing 104 is formed two plastic clam shells 134 which clampto the end of the elongate body 102. The rear housing 104 comprises aforward mount section 136 and rear handle section 138. A battery mount140 is formed on the lower surface of the mount section of the rearhousing 104. A battery pack 142 can be slid in a forward direction(Arrow M in FIG. 19) onto the battery mount 140 to attach it to the rearhousing 104 and in a rearward direction to detach it from the batterymount 140. The design of the battery mount 140 and battery 142 are knownin art and therefore will not be described in any more detail.

Control electronics 144 for the motor 114 are mounted inside of forwardmount 136 section of the rear housing 104. The control electronics 144are connected to the motor 114 via an electric cable 146 which passesthrough a second passageway 148 of the elongate body 102 through thelength of the elongate body 102. The control electronics 144 control theoperation of the brushless motor 114.

A lock on/lock off switch 150 is mounted on the top of rear housing 104where the rear handle section 138 connects to the forward mount section136. An operator can use the lock on/lock off switch 150 to activate themotor 114.

An operator can support the pole sander by grasping the rear handlesection 138 of the rear housing 104 in one hand and the elongate body102 in the other. The operator can switch the pole sander on or offusing the thumb of the hand grasping the rear handle section 138.

A vacuum connection nozzle 152 is mounted on the rear of the rearhousing 104 which connects to a first passageway 154 which extendsthrough the length of the elongate body 102. The other end of the secondpassage 154 connects to the flexible pipe 128. A vacuum cleaner (notshown) can be connected to the nozzle 152 and draw air from under thehood 112, through the flexible pipe 128, through the first passage 154in the elongate body 102, through the nozzle 152 and into a vacuumcleaner.

The hood 112 will now be described with reference to FIGS. 4 to 6.

The hood 112 comprises a circular plate 156 which extends radially froma central circular hole 158 through which the output spindle 118projects. Formed on the underside of the plate 156 around the edge is aperipheral wall 160 which projects perpendicularly to the plane of thecircular plate 156. An inner circular inner wall 162 is formed on theunderside of the plate 156 in close proximity to and concentrically withthe peripheral wall 160. The inner wall 162 has the same height as theperipheral wall 160 and extends in the same direction that is parallelto the peripheral wall 160. A circular trough 164 is formed between thetwo walls 160, 162. Six rectangular apertures 166 are formed through thebase of the trough 164. The apertures 166 are located equidistantlyaround the centre of the plate 156 in a symmetrical fashion. A chamber166 is formed between the inner wall 162 and the underside of the plate156.

Formed through the plate 156 between the inner wall 162 and the centralhole is an arc shaped aperture 130 which allows air and debris to passthrough the plate 156. The aperture 130 has three edges, a firststraight edge 170 which extends tangentially to the longitudinal axis126 of the output spindle 118, a second edge 172 of equal length whichextends from the end of the first edge 170, perpendicularly to the firstedge 170, in a direction away from the longitudinal axis 126 of theoutput spindle 118, and a third curved edge 174 extending between theends of the first and second edges 170, 172. The circular plate 156 hasa radius R. The whole of the arc shaped aperture 130 is located at adistance of less than half of the radius from longitudinal axis 126 ofthe output spindle 118 or the centre of the plate 156 (<R/2).

Integrally formed on the top side of the plate 156 is a curved wall 178which forms a tubular passageway 176 from the arc shaped aperture 168 toan opening where the flexible pipe 128 is attached. Where the tubularpassageway 176 connects to the arc shaped aperture 130, it is shaped toengage with the arc shaped aperture 130 at certain angles to maximisethe air flow efficiency.

Referring to FIGS. 26A and 26B, the first angle of the exit of thetubular passageway 176 is located in a vertical plane 300 which passesthrough axis of rotation 126 of the output spindle 118 across the end ofthe tubular passage 176 adjacent the arc shaped aperture 168. The angle302 in this plane 300 between the axis of rotation 126 of the outputspindle 128 and the direction of the tubular passageway 176 is less than90 degrees (perpendicular) but greater than 0 degrees (parallel) and isideally between 20 degrees and 60 degrees.

Referring to FIGS. 27A and 27B, the second angle of the exit of thetubular passageway 176 is located in a vertical plane 304 which extendstangentially to the axis of rotation 126 of the output spindle 128, thepart of the plane 304 which passes through the exit of the tubularpassageway 176 being the closest part to the axis of rotation 126 of theoutput spindle 118. The angle 308 in this plane 304 between the plane ofthe circular plate 156 of the hood 112 and the direction of the tubularpassage 176 in the turning direction 306 of the platen 116 is less than90 degrees and is ideally between 20 degrees and 60 degrees.

The hood 112 is formed in a one-piece construction from plastic.

The brush ring 132 will now be described with reference to 6 to 8.

The brush ring 132 comprises a plastic circular ring 180 which is sizedso that it is capable of locating inside of the trough 164. Extendingperpendicularly from the bottom side of the ring 180 are a series ofbristles 182. Attached to the opposite top side of the brush ring 132are the ends 184 of six leaf springs 186. The leaf springs 186 areformed from sheet metal and are resiliently deformable in a directionperpendicular to the plane of the sheet. The leaf springs 186 comprisesa central section 188 located between two end sections 184, 190. The endsections 184, 190 extend in a direction parallel to the top surface ofthe ring 180. The central section 188 of the leaf springs 186 extendsupwardly at a slight angle to the plane of the circular ring 180. Eachcentral section 188 of each leaf spring 186 extends through therectangular aperture 166 in the trough 164 and attaches to the top side194 of the plate 156 as shown in FIG. 8. The leaf springs 186 bias thering 180 to a position where it is located at a distance from the baseof the trough 164 as shown in FIG. 6. In this position, the bristles 182project below the hood 112. When the sanding head 100 is placed againsta work surface, the bristles 182 engage with the work surface. When thesanding head 100 is pushed against the work surface, the brush ring 132is pushed into the trough 164 against the biasing force of the leafsprings 186. The leaf springs 186 ensure that the bristles 182 arebiased into engagement with the work surface. When the sanding head 100is removed from the surface, the brush ring 132 returns to its originalposition due to the resilient nature of the leaf springs 186.

A plastic cover 195 is located over the topside of the hood 112enclosing the ends 190 of the leaf springs 186 attached to the top side194.

The telescopic elongate body 102 will now be described with reference toFIGS. 1 to 3 and 9 to 14.

The pole sander has an elongate body 102 comprising a first pole 196which is capable of sliding in and out of a second pole 198 in atelescopic manner to enable the length of the pole sander to beadjusted. A locking mechanism 200 is used to lock the first pole 196 tothe second pole 198 when the two poles 196, 198 have been telescoped toa preferred length.

Inside both of the poles 196, 198 are two passageways 148, 154 which runthe length of the both poles 196, 198. The first larger passageway 154is used to transport air (due to suction) and entrained dust and debris,generated during the use of the pole sander, through the poles 196, 198from the working end to a vacuum nozzle 152 at the opposite end, thenozzle 152 being connected to a vacuum cleaner. The second smallerpassageway 148 is used as a conduit for electric cable 146 which providepower and control signals from a control electronics 144 for theelectric motor 114 mounted in the sanding head 100. The cable 146 canalso transmit sensor signals from the motor 114 to the controlelectronics 144.

The first pole 196 comprises a single aluminium tube with an internalwall 202 located inside of the tube, which runs the length of the tubeto form the two passageways 148, 154 which run the length of the firstpole 196. The first larger passageway 154 forms part of the firstpassageway which is used to transport air. The second smaller passageway148 forms part of the passageway which is used as a conduit for theelectric cable 146. A first seal 204 attaches to the end of the firstpole 196 which is inserted into the second pole 198. The shape of theseal 204 corresponds to that of the end of the aluminium tube andinternal wall 202. The first seal 204 provides a seal between the firstpole 196 and the second pole 198. It also acts as a slide bearing.

The second pole 198 comprises two aluminium tubes 206, 208. The secondaluminium tube 208 locates inside of the first aluminium tube 206 andruns the full length of the first tube 206, their longitudinal axesbeing parallel to each other. The second aluminium tube 208 forms partof the first passageway which is used to transport air and dust ordebris. The first aluminium tube 206 forms part of the passageway 154which is used as a conduit. A second seal 210 is attached to the end ofthe first aluminium tube 206 into which the first pole 196 is inserted.The shape of the second seal 210 corresponds to that of the end of thealuminium tube 206. A third seal 212 is attached to the end of thesecond aluminium tube 208 which is inserted into the second passage 148way of the first pole 196. The shape of the third seal 212 correspondsto that of the end of the second aluminium tube 208. The seals 210, 212provides a seal between the first pole 196 and the second pole 198. Theyalso act as slide bearings. The two tubes 206, 208 are connected to eachother at their ends remote from the seals 210, 212 so that relativemovement between the two tubes 206, 208 is prevented.

The poles 196, 198 are assembled as following. The end with the thirdseal 212 of the second aluminium tube 208 of the second pole 198 isinserted into the second passageway 148 of the first pole 196 throughthe seal 212. The end of the first pole 196 with the first seal 204,with the second aluminium tube 208 inside of it, is then inserted intothe end of the first aluminium tube 206 of the second pole 198 with thesecond seal 212.

The larger passageway 154 in the first pole 196 connects directly to anend of the flexible tube via a collar 214. The larger passageway 154 inthe second pole 198 connects to an end of the vacuum attachment nozzle152 via an extension tube 216.

As the poles 196, 198 are made from aluminium, they are conductive. Assuch the poles, 196, 198 are electrically grounded by being electricallyconnected to neutral in the electronic control electronics 144 in therear housing 104. in order to ensure that the whole of elongate body 102is grounded, ideally, the seals 204, 210, 212 are manufactured fromelectrically conductive material. This ensures a good electricalconnection between the two poles 196, 198.

In addition, or as an alternative, metal contacts 218 such as leafsprings can be located between the telescopic poles 196, 198 to ensureelectrical conductivity between the poles 196, 198.

The pivot mechanism 110 will now be described with reference to FIGS. 4,15 and 16.

Attached to the end of the first pole 196 in a fixed manner is an endhousing 220 (see FIGS. 1 and 2) comprising two clam shells 222 attachedto each other using screws (only one clam shell is shown in FIG. 4). Thepivot mechanism 110 connects the sanding head 100 to the first pole 196via the end housing 220.

The pivot mechanism 110 comprises a fork 224 having two arms 226, acentral interconnecting section 228 and a pole support section 230. Thetwo arms 226 extend in parallel in a forward direction from the ends ofthe central interconnecting section 228 in a symmetrical manner. Thepole support section 230 connects to the centre of the interconnectionsection 228 on the opposite side of the two arms 226 and projects in arearward direction opposite but parallel to that of the two arms 226.

Formed in each side of the gear housing 122 in a symmetrical manner arethreaded apertures. The axis 232 of the of the apertures are alignedwith each other and are horizontal. Formed in the ends of the two arms226 are apertures. When the fork 224 is attached to the sanding head100, the ends of the two arms 226 align with the apertures formed in thegear housing. A bolt 234 is passed through each aperture in the end ofeach arm 226 and screw into the threaded aperture in the side of thegear housing 122 to attach the fork 224 in a pivotal manner. The fork224 can pivot around the bolts 234 about a horizontal sideways axis 232.

Rigidly mounted in a recess formed in the end of the pole supportsection 228 is the rear half of an axle 234. The axle 234 projectsrearwardly. Formed in the end housing 220 is an elongate recess 236. Therecess 236 extends in a direction parallel to the longitudinal axis ofthe first pole 196. The forward half of the axle 234 is mounted insideof the recess 236 via two bearings 240 supported by the end housing inthe side walls of the recess. The bearings 240 allow the axle to rotatewithin the recess. The axle can rotate about an axis which is parallelto the longitudinal axis of the first pole 196 and which passes throughthe length of the second smaller passage 148 of the elongate body 102.This allows the fork 224, together with sanding head 100, to pivot aboutan axis which is parallel to the longitudinal axis of the first pole 196and which passes through the length of the second smaller passage 148 ofthe elongate body 102. The axis also crosses the output axis 126 of thedrive spindle.

The sanding head 100 has a centre of gravity 242. As best seen in FIG.15, the axis of pivot 232 of the fork 224 on the sanding head 100 islocated forward (distance D in FIG. 15) of the centre of gravity 242.Furthermore, the axis of pivot 232 of the fork 224 on the sanding head100 100 is located forward of the drive axis 126 of the output spindle118. This allows the sanding head 100, which can freely rotate about thebolts 234, to automatically pivot to an angular position where it isparallel to a wall when the sanding head 100 is raised by an operator.

When the plane of the platen 116 is parallel to the longitudinal axis ofthe elongate body 102 as shown in FIG. 16, the axis of rotation of theaxle is located below the centre of gravity 242 of the of the sandinghead 100.

The design of the platen 116 will now be described with reference toFIGS. 17 and 18.

The platen 116 comprises a plastic disc 244 with a metal insert 246located at the centre. Attached to the bottom of disk is layer made of asoft foam 248. Attached on the opposite side of the soft foam layer is asheet of Velcro 250. The Velcro 250 is used to attach the sandpaper tothe platen 116.

The platen 116 is attached to the output spindle 118 using a bolt 252.The platen 116 is circular and extends radially from the drive axis 126in a direction perpendicular to the drive axis 126. Two sets of airholes 254, 256 are formed through the platen 116 to allow air and debristo pass through the platen 116. The first set 254 are located towardsthe outer edge of the platen and in a symmetrical manner around the axis126. The holes 254 of the first set are tear shaped with the narrowerend pointing towards the centre. The straight sides of the holes 254align with the centre of the platen 116. The second set of holes 256 arelocated between the first set 254 and the centre of the platen 116 in asymmetrical manner. The holes 256 of the second set are smaller thanthose of the first set. The holes 256 of the second set are tear shapedwith the narrower end pointing towards the centre. The straight sides ofthe holes 256 align with the centre of the plate 116.

Referring to FIG. 6A, a space 258 is formed between the top of theplaten 116 and the underside of the hood 112. In the present design, thesize H of the space is kept to a minimum. This ensures that the airspeed above the platen 116 is kept as high as possible. If the air speedslows, entrained dust and debris will deposit on the surface of theunderside of the hood 112 and therefore will build up. By keeping theair speed high, the dust remains entrained and therefore can be drawnout the flexible pipe 128 due to the suction from a vacuum cleaner.

The air flow around the rotating platen 116 is improved due to the innercircular inner wall 162 which is adjacent the outer edge of the platen116. The inner wall 162 locates between the edge of the paten and thebristles 182 of the brush ring 132. The inner wall 162 guides the movingair in a smooth manner and minimises the amount of contact between themoving air and the bristles 182 of the brush ring 132. If the moving airwere to come into contact with the bristles 182, the air flow wouldbecome non-uniform as its passes through the bristles 182. Furthermore,the use of the inner wall 162 to separate the bristles 182 from the edgeof the platen 116 minimises the amount of dust and debris that collectswithin the bristles 182.

The cross-sectional area of the gap 260 between the inner wall 162 andthe edge of the platen 116 (shown by the hatchings 262 in FIG. 6B) isthe same as that of the cross-sectional area of the flexible pipe 128which in turn is the same as that of the first passageway 154 way in thetwo poles 196, 198.

Referring to FIG. 19, the second pole 198 extends into the mount section136 of the rear housing 104. A part 270 of the side wall first aluminiumtube 206 of the second pole 198 has been removed to expose the surfaceof the second aluminium tube 208. The control electronics 144 aremounted in a control module. Where the part 270 of the first aluminiumtube has been removed, the control module 144 is mounted inside of thefirst aluminium tube 206 adjacent the second aluminium tube 208. Thisenables heat generated by the electronic module 144 to be transferred tothe second aluminium tube 208 which is a good heat conductor andtransfer the heat away from the control module 144. Furthermore, duringthe operation of the pole sander, air is drawn through the secondaluminium tube 208 by a vacuum cleaner. The air flow acts to cool thesecond aluminium tube 208 which in turn acts to cool the electronicmodule 144.

The control electronics 144 are connected directly to the motor 114using a single electrical cable 146 which carries the wires use toprovide the electrical current to the windings of the brushless motor114. One end of the cable 146 connects directly to the controlelectronics 144 via a soldering tag 272 which connects to electricinterface 274. The other end connects directly to the motor 114. Thecable 146 is continuous with no plugs or connectors being used so asavoid interfering with the signals generated by the control electronics144 which are sent down the cable 146 to operate the motor 114. Thecable 146 can also transmit sensor signals (such as temperature, angularposition of the rotor etc.) from the motor to the control electronics. Acentral section 276 of the cable 146 located inside of the two poles196, 198 is helical to enable the length of the cable 146 in a directionparallel to the longitudinal axis of the poles 196, 198 to extend orreduce depending on the relative telescopic positions of the two poles196, 198. When the cable 146 exit the first pole 196 and pass across thepivot mechanism 110, it locates against the side of flexible pipe 128 asshown in FIG. 21. In order to maintain the position of the cable 146relative to the flexible pipe 128, a tubular sheaf 278 surrounds boththe cable 146 and the flexible pipe 128 as shown in FIGS. 26 and 27.

An extension tube 280 connects to the end of the second aluminium tube208 of the second pole 198 which extends the first passageway 154 of thesecond pole 198 through the rear handle section 138 of the rear housing104 and projects rearwardly of the handle section 138. A vacuum nozzle152 is releasably attachable to the end of the extension tube 280 via aclip 282. The clip 282 comprises a first part formed on the vacuumnozzle 152 and a second part formed on the end of the extension tube280. The first part comprises two pins 284, each pin 284 being mountedon the end of a resiliently deformable leg 286. The second part comprisetwo holes 288 formed through the side wall of the end of the extensiontube 280 in corresponding locations to the pins 284. To attach thevacuum nozzle 152, the legs 286 are bent inwardly so that the pins 284can slide inside of the end of the extension tube 280 as the vacuumnozzle 152 is slid into the extension tube 280. When the pins 284 alignwith the holes 288, the pins 284 are biased into the holes 288 by theresilient legs 286 bending back to their original position. Whilst thepins 284 are located in the holes 288, the vacuum nozzle 152 remainsattached to the extension tube 280. To detach the vacuum nozzle 152 thepins 284 are pushed back into the apertures to disengage them from theholes 288. The nozzle 152 is slid out of the extension tube 280. Thevacuum nozzle 152 can be attached to the hose of a vacuum cleaner. Asthe nozzle 152 can be easily attached and detached, a suitable design ofnozzle 152 can be chosen depending on the type of vacuum cleanerutilised. Furthermore, if the nozzle 152 breaks it can be easilyreplaced.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

1. A pole sander comprising: an elongate body having a first end and asecond end; a sanding head attached via a pivot mechanism to the firstend of the elongate body, wherein the sanding head comprises a hoodhaving a plate, a chamber formed under the plate, and an output spindleprojecting into the chamber; an electric motor mounted on the sandinghead and configured to rotatably drive the output spindle; a rearhousing mounted on or proximate the second end of the elongate body, therear housing including control electronics therein configured to controlthe motor via an electric cable; a tubular passage coupled to anaperture formed though the plate; a passageway formed in the elongatebody to transport air; and a flexible pipe connecting the tubularpassage to the elongate body to provide an airflow path between thechamber and the passageway, wherein at least a part of the electriccable locates against a side of the flexible pipe.
 2. The pole sander ofclaim 1, further comprising a tubular sheaf surrounding both theflexible pipe and the at least part of the cable to fixedly support theelectrical cable against the flexible pipe.
 3. The pole sander of claim1, wherein the motor is connected to the control electronics via asingle continuous electric cable via which the electronic controlsignals and/or sensor signals are transmitted.
 4. The pole sander ofclaim 1, wherein the elongate body comprises a secondary passagewayextending substantially through the length of the elongate body andforming a conduit through which the electric cable passes.
 5. The polesander of claim 1, wherein the elongate body comprises a first pole anda second pole are capable of sliding in and out of each other in atelescopic manner.
 6. The pole sander of claim 5, wherein at least oneof the first pole and/or the second pole is manufactured from metaltubing.
 7. The pole sander of claim 5, wherein the first pole comprisesa single aluminium tube with an internal wall to form a part of thepassageway and a part of a secondary passageway.
 8. The pole sander ofclaim 7, wherein the second pole comprises a first tube and a secondtube mounted in parallel to the first tube inside of the first tube. 9.The pole sander of claim 8, wherein an end of the second tube of thesecond pole locates inside a part of the passageway located inside thefirst pole, and wherein the second tube and an internal wall of thefirst pole locate inside the first tube.
 10. The pole sander of claim 9,wherein the second tube of the second pole forms part of the passageway.11. The pole sander of claim 9, wherein the first tube of the secondpole forms a conduit that is a part of the secondary passageway.
 12. Thepole sander of claim 11, wherein the electric cable passes through theconduit.
 13. The pole sander of claim 12, wherein at least a part of theelectric cable located inside the conduit is helical.
 14. A pole sandercomprising: an elongate body having a first end and a second end; afront housing mounted on or approximate the first end of the elongatebody; a sanding head attached via a pivot mechanism to the fronthousing, wherein the sanding head comprises a hood having a plate, achamber formed under the plate, and an output spindle rotatablyprojecting into the chamber; an electric motor mounted on the sandinghead configured to rotatably drive the output spindle; a rear housingmounted on or proximate the second end of the elongate body, the rearhousing including control electronics therein configured to control themotor; a tubular passage coupled to an aperture formed though the plate;a first passageway formed in the elongate body to transport air; aflexible pipe connecting the tubular passage to the front housing toprovide an airflow path between the chamber and the first passageway;and a second passageway formed in the elongate body, wherein the controlelectronics are electrically coupled to the electric motor via a cabledisposed within the second passageway.
 15. The pole sander of claim 14,wherein the cable is a single continuous cable extending from theelectric motor to the rear housing.
 16. The pole sander of claim 14,wherein a part of the electric cable located between the electric motorand the front housing is secured against a side of the flexible pipe.17. The pole sander of claim 16, further comprising a tubular sheafsurrounding both the flexible pipe and the at least part of the cable tofixedly support the electrical cable against the flexible pipe.
 18. Thepole sander of claim 14, wherein the elongate body comprises a firstpole and a second pole are capable of sliding in and out of each otherin a telescopic manner.
 19. The pole sander of claim 18, wherein thefirst pole comprises an internal wall to form a part of the firstpassageway and a part of a secondary passageway.
 20. The pole sander ofclaim 19, wherein the second pole comprises a first tube and a secondtube mounted in parallel to the first tube inside of the first tube.